Microstructure-controlled mechanical behavior of autogenous laser-welded IN625-AISI 304L dissimilar joints Niraj Kumar, Prakash Kumar, Aman Verma, Amit Kumar Materials Today Communications, 2026 An autogenous laser-welded dissimilar joint between Inconel 625 (IN625) and AISI 304 L austenitic stainless steel was produced to evaluate its microstructural changes and high-temperature structural performance. The laser weld exhibited full penetration with defect-free fusion and narrow weld fusion characteristics, explaining the high energy density and rapid solidification inherent to the process. Microstructural characterization highlights the heterogeneous solidification characteristics in the weld metals (WM), which solidify as cellular and columnar microstructures governed by localized thermal gradients and elemental compositions. Pronounced microsegregation of Nb and Mo occurred within interdendritic regions, promoting the formation of Laves phases, NbC, and Cr-rich carbides, as confirmed by SEM/EDS and elemental mapping. The weld fusion region near the AISI 304 L exhibits the occurrence of an unmixed zone (UZ) and partially mixed zone (PMZ), whereas the interfacial region near the IN625 exhibits the presence of PMZ along with uniformly distributed secondary phases. Mechanical assessment demonstrates a Vickers microhardness (HV) gradient across the weld joint, with enhanced WM hardness of 210 HV due to solid solution strengthening and interdendritic phases. Further, the destructive room temperature (RT) tensile testing indicates WM failure with an acceptable average tensile strength of 664.7±4.5 MPa and percentage elongation of 52±5.5%, comparable to the weaker base metal (AISI 304 L). The dissimilar weld illustrates the superior high-temperature (HT) tensile strength at 550 ºC (397 MPa), 600 ºC (359 MPa), and 650 ºC (304 MPa). Moreover, the reduced average impact toughness of the laser weld, i.e., 62± 3 J, is attributed to the dendritic heterogeneity and brittle secondary phases. Overall, the results demonstrate that laser welding enables sound IN625–304 L dissimilar joints with acceptable strength, though interdendritic segregation and precipitate formation remain critical factors influencing toughness. • The defect-free dissimilar laser-welded joint between Inconel 625 and AISI 304L was fabricated with almost no metallurgical defects. • The dissimilar laser weld demonstrates the segregation of elements forming laves phases and carbide phases across the weld matrix, grain boundaries, and interdendritic spaces. • High temperature tensile behaviour was investigated to highlight the mechanical stability under AUSC-relevant service conditions.
Enhancing Cladding Performance: Chromium Oxide and Alumina Powders with PVA Binder in GTAW Welding Suresh Pratap, Prakash Kumar Advanced Coating and Cladding Technologies, 2026 This chapter investigated the effectiveness of chromium oxide (Cr2O3) and alumina (Al2O3) powders as cladding materials with polyvinyl alcohol (PVA) as a binder. These materials were chosen for their exceptional properties, with chromium oxide being known as the hardest oxide and exhibiting a low friction coefficient, adiabatic characteristics, and corrosion resistance. Gas tungsten arc welding (GTAW) was used to achieve high-quality mild steel cladding, followed by a hardness and microstructural study. The results showed that wire feed rate and welding voltage significantly affected dilution, amount of penetration, weld bead height, and width. The average hardness of the Cr2O3–Al2O3 cladded zone was measured to be 507.3 HV and 573.3 HV, respectively, at 100 N load. These hardness measurements are particularly impressive, indicating a significant improvement in wear resistance and durability in the cladded zone. These findings suggest that using chromium oxide and alumina powders as cladding materials can effectively improve the hardness and other important properties of the cladded zone, making it a promising method for industrial applications.
Microstructural and mechanical investigation of dissimilar U-groove weld of IN 718/ASS 304L employing ERNiCr-3 filler Niraj Kumar, Prakash Kumar, Sachin Sirohi, Shailesh M. Pandey, Chandan Pandey Journal of Adhesion Science and Technology, 2026 This study investigates the dissimilar welding of Inconel 718 (IN 718) and austenitic stainless steel 304L (ASS 304L) using Gas Tungsten Arc Welding (GTAW) with Ni-based filler ERNiCr-3. IN 718 is valued for its high-temperature stability, oxidation, and corrosion resistance, while ASS 304L offers excellent ductility, formability, and corrosion resistance. The objective is to evaluate the impact of ERNiCr-3 on the weld’s metallurgical and mechanical attributes. The materials, prepared with U-groove edges, were optimized for manual multi-pass welding. Microstructural analysis revealed an austenitic matrix with dispersed Ti(CN) and NbC precipitates, enhancing strength through dispersion-strengthening mechanisms, with no solidification cracking due to Nb presence. FESEM/EDS and colour mapping identified elemental migration and stable carbide formation at the weld interfaces. Mechanical testing revealed uniform hardness within the weld zone and tensile resistance of 510 MPa, underscoring the robustness of ERNiCr-3 weld metal. These results indicate that ERNiCr-3 is highly effective for producing superior quality dissimilar welds amidst IN 718/ASS 304L, making it suitable for applications in elevated-temperature and mechanically demanding environments.
Modeling of Human-Induced Dynamic Bouncing Force Using a Self-Sustained Nonlinear Oscillator Sunil Kumar Maurya, Anil Kumar, Prakash Kumar International Journal of Structural Stability and Dynamics, 2025 This paper proposed a single-degree-of-freedom self-sustained nonlinear oscillator capable of precisely predicting the bouncing force induced by a person during bouncing activity on a flat and rigid surface. A bouncing person produces essential internal energy required to maintain its motion, so it can be modeled as a self-sustained oscillator that can generate (i) the stable limit cycle, (ii) the periodic bouncing force signal, and (iii) the self-sustained motion. A hybrid Van der Pol–Rayleigh oscillator added with two quadratic and one cubic nonlinear terms has been derived to yield desired softening and hardening effects as well as even and odd harmonics, as observed from the analysis of experimental bouncing force data. The force applied on the surface corresponds to its restoring force. The stability analysis of the oscillator has been performed using the energy balance and perturbation methods. The model parameters are extracted from the experimental bouncing force data resulting from a bouncing test on a group of seven subjects with shoe insoles at six different frequencies guided by a metronome. The bootstrapping method has been performed to examine the convergence of mean values of each model parameter by increasing the cardinality of the experimental set. The bouncing force signals produced by the proposed model and experimental results demonstrate an excellent agreement.
Optimization of Gas Metal Arc Welding-Based Wire Arc Additive Manufacturing Parameters for Inconel 617 over SS304L: Experimental, Microstructural, and Machine Learning Insights MK Perumal, N Kumar, P Kumar, SK Mishra, S Kumar, M Giri Journal of Materials Engineering and Performance, 1-13 , 2026 2026
High-temperature rupture behaviour of the laser welded P22 steel weldments S Sirohi, S Kumar, A Kumar, P Kumar, C Pandey Welding International, 1-11 , 2026 2026
Microstructure-Controlled Mechanical Behavior of Autogenous Laser-Welded IN625-AISI 304 L Dissimilar Joints N Kumar, P Kumar, A Verma, A Kumar Materials Today Communications, 115008 , 2026 2026
Analytical characterization of self sustained nonlinear oscillators modelling human walking and bouncing V Nevash, P Kumar, C Dangi arXiv preprint arXiv:2602.19029 , 2026 2026
Microstructural and mechanical investigation of dissimilar U-groove weld of IN 718/ASS 304L employing ERNiCr-3 filler N Kumar, P Kumar, S Sirohi, SM Pandey, C Pandey Journal of Adhesion Science and Technology 40 (3), 650-667 , 2026 2026 Citations: 6
Dissimilar gas metal arc welding (GMAW) of Inconel 718 and 304L stainless steel: a comparative study of ERNiCrCoMo-1 and ERNiCr-3 filler metals N Kumar, P Kumar, D Fydrych, C Pandey International Journal of Pressure Vessels and Piping, 105732 , 2025 2025 Citations: 8
Circular Fashion Supply Chains: An Empirical Study on Overcoming Circular Economy Challenges Through Coordination V Akhil, T Niranjan, V Verma, P Kumar, S Rajak Advances in Industrial and Manufacturing Systems: Select Proceedings of RADM … , 2025 2025
Comparative study on the SMAW dissimilar welding of IN718 and ASS304L using ENiCrCoMo-1 and ENiCrFe-3 electrodes N Kumar, P Kumar, C Pandey Materials Chemistry and Physics 343, 131080 , 2025 2025 Citations: 10
Modeling of Human-Induced Dynamic Bouncing Force Using a Self-Sustained Nonlinear Oscillator SK Maurya, A Kumar, P Kumar International Journal of Structural Stability and Dynamics 25 (17), 2550178 , 2025 2025 Citations: 3
Impact of buttering on microstructure and mechanical behavior of IN718-ASS304L dissimilar joint N Kumar, P Kumar, C Pandey Metallurgical and Materials Transactions A 56 (8), 3366-3390 , 2025 2025 Citations: 13
Investigating the metallurgical and microstructural characteristics of pulsed GMAW welds in IN718 and ASS304L with ERNiCr-3 filler N Kumar, P Kumar, A Kumar, C Pandey Archives of Civil and Mechanical Engineering 25 (4), 186 , 2025 2025 Citations: 8
Machine learning applications in inventory management: A case study P Kumar, VN Bhonde, S Rajak, M Sundararaman Industry 4.0 for Manufacturing Systems, 137-159 , 2025 2025 Citations: 5
An assessment of barriers to integrate lean six sigma and industry 4.0 in manufacturing environment: case based approach S Rajak, P Kumar, A Modi, V Swarnakar, J Antony, M Sony International Journal of Computer Integrated Manufacturing 38 (3), 386-407 , 2025 2025 Citations: 24
Role of microstructure evolution during welding on mechanical properties and residual stresses of the Inconel 718 and austenitic stainless steel 304L dissimilar weld joint N Kumar, P Kumar, RS Vidyarthy, C Pandey Metallurgical and Materials Transactions A 55 (11), 4543-4570 , 2024 2024 Citations: 25
Influence of filler materials on GTAW dissimilar welds: Inconel 718 and austenitic stainless steel 304L N Kumar, P Kumar, C Pandey Archives of Civil and Mechanical Engineering 24 (4), 231 , 2024 2024 Citations: 31
Investigation on microstructural and mechanical integrity of GTAW dissimilar welded joint of IN 718/ASS 304L using Ni-based filler IN 625 using EBSD and DHD techniques N Kumar, P Kumar International Journal of Pressure Vessels and Piping 209, 105213 , 2024 2024 Citations: 25
Numerical analysis of design factors in manufacturing for improved energy efficiency AS Dwivedi, P Kumar, JH Luna-Domínguez, RC Cozza, V Verma Sustainability in Smart Manufacturing, 185-200 , 2024 2024
Study on effect of double austenitization treatment on fracture morphology tensile tested nuclear grade P92 steel (Expression of Concern of Vol 96, Pg 158, 2019) C Pandey, MM Mahapatra, P Kumar, P Kumar, N Saini, JG Thakare, ... ENGINEERING FAILURE ANALYSIS 158 , 2024 2024
Numerical and experimental investigation of autogenous GTAW weld between IN 718/ASS 304L N Kumar, P Kumar, RS Vidyarthy, C Pandey International Journal on Interactive Design and Manufacturing (IJIDeM) 18 (3 … , 2024 2024 Citations: 14
Assessment of the structural integrity of a laser weld joint of Inconel 718 and ASS 304L N Kumar, P Kumar, R Upadhyaya, S Kumar, C Panday Sustainability 15 (5), 3903 , 2023 2023 Citations: 17
MOST CITED SCHOLAR PUBLICATIONS
Dissimilar welding of inconel alloys with austenitic stainless-steel: a review N Kumar, C Pandey, P Kumar Journal of Pressure Vessel Technology 145 (1), 011506 , 2023 2023 Citations: 98
Study on effect of double austenitization treatment on fracture morphology tensile tested nuclear grade P92 steel C Pandey, MM Mahapatra, P Kumar, P Kumar, N Saini, JG Thakare, ... Engineering Failure Analysis 96, 158-167 , 2019 2019 Citations: 84
A modified hybrid Van der Pol–Duffing–Rayleigh oscillator for modelling the lateral walking force on a rigid floor P Kumar, A Kumar, S Erlicher Physica D: Nonlinear Phenomena 358, 1-14 , 2017 2017 Citations: 44
Modelling vertical human walking forces using self-sustained oscillator P Kumar, A Kumar, V Racic, S Erlicher Mechanical Systems and Signal Processing 99, 345-363 , 2018 2018 Citations: 38
Influence of filler materials on GTAW dissimilar welds: Inconel 718 and austenitic stainless steel 304L N Kumar, P Kumar, C Pandey Archives of Civil and Mechanical Engineering 24 (4), 231 , 2024 2024 Citations: 31
Role of microstructure evolution during welding on mechanical properties and residual stresses of the Inconel 718 and austenitic stainless steel 304L dissimilar weld joint N Kumar, P Kumar, RS Vidyarthy, C Pandey Metallurgical and Materials Transactions A 55 (11), 4543-4570 , 2024 2024 Citations: 25
Investigation on microstructural and mechanical integrity of GTAW dissimilar welded joint of IN 718/ASS 304L using Ni-based filler IN 625 using EBSD and DHD techniques N Kumar, P Kumar International Journal of Pressure Vessels and Piping 209, 105213 , 2024 2024 Citations: 25
An assessment of barriers to integrate lean six sigma and industry 4.0 in manufacturing environment: case based approach S Rajak, P Kumar, A Modi, V Swarnakar, J Antony, M Sony International Journal of Computer Integrated Manufacturing 38 (3), 386-407 , 2025 2025 Citations: 24
Analysis of surface integrity and dimensional accuracy in EDM of P91 steels P Kumar, S Dewangan, C Pandey Materials Today: Proceedings 33, 5378-5383 , 2020 2020 Citations: 23
Characterization of the soft zone in dissimilar welds joint of 2.25 Cr-1Mo and lean duplex LDX2101 steel C Pandey, JG Thakare, PK Taraphdar, P Kumar, A Gupta, S Sirohi Fusion Engineering and Design 163, 112147 , 2021 2021 Citations: 22
Human induced vibration in structures P Kumar, A Kumar Int. J. Mech. Eng. Robot. Res 1 (1), 44-54 , 2014 2014 Citations: 19
Assessment of the structural integrity of a laser weld joint of Inconel 718 and ASS 304L N Kumar, P Kumar, R Upadhyaya, S Kumar, C Panday Sustainability 15 (5), 3903 , 2023 2023 Citations: 17
Modeling of Longitudinal Human Walking Force Using Self-Sustained Oscillator P Kumar, A Kumar, V Racic International Journal of Structural Stability and Dynamics 18 (6), 1850080 , 2017 2017 Citations: 17
Role of Ni-based filler on charpy impact toughness of the P91 welds joint S Sirohi, P Kumar, A Gupta, S Kumar, C Pandey Materials Today: Proceedings 44, 1043-1049 , 2021 2021 Citations: 15
Numerical and experimental investigation of autogenous GTAW weld between IN 718/ASS 304L N Kumar, P Kumar, RS Vidyarthy, C Pandey International Journal on Interactive Design and Manufacturing (IJIDeM) 18 (3 … , 2024 2024 Citations: 14
Impact of buttering on microstructure and mechanical behavior of IN718-ASS304L dissimilar joint N Kumar, P Kumar, C Pandey Metallurgical and Materials Transactions A 56 (8), 3366-3390 , 2025 2025 Citations: 13
Characterization of microstructure and mechanical properties of Cr-Mo Grade P22/P91 steel dissimilar welds for supercritical power plant application S Sirohi, A Sauraw, A Kumar, S Kumar, T Rajasekaran, P Kumar, ... Journal of Materials Engineering and Performance 31 (9), 7353-7367 , 2022 2022 Citations: 13
Study on the effect of the grain refinement on mechanical properties of the P92 welded joint C Pandey, N Kumar, S Sirohi, T Rajasekaran, S Kumar, P Kumar Journal of Materials Engineering and Performance 31 (6), 4385-4404 , 2022 2022 Citations: 13
A Nonlinear Oscillator Model to Generate Lateral Walking Force on a Rigid Flat Surface P Kumar, A Kumar, S Erlicher International Journal of Structural Stability and Dynamics 18 (2), 1850020 , 2017 2017 Citations: 13
Transient vibration reduction of a powertrain using MRE based adaptive tuned vibration absorber MK Sethi, P Kumar, A Kumar Procedia Engineering 144, 689-696 , 2016 2016 Citations: 11
